U.S. patent application number 12/617710 was filed with the patent office on 2010-05-06 for label sheet assembly and method of making the same.
Invention is credited to Florence M. Brisee, Jerry G. Hodsdon, Le H. Hong, Michael Novak, Gildardo Ramirez Villegas, Ronald Ugolick, Alejandro G. Veyna Hernandez.
Application Number | 20100109316 12/617710 |
Document ID | / |
Family ID | 43414841 |
Filed Date | 2010-05-06 |
United States Patent
Application |
20100109316 |
Kind Code |
A1 |
Hong; Le H. ; et
al. |
May 6, 2010 |
LABEL SHEET ASSEMBLY AND METHOD OF MAKING THE SAME
Abstract
A label sheet assembly including a liner sheet, a carrier sheet,
and a facestock sheet. The facestock sheet includes cut lines
defining labels and cut lines defining at least a portion of a
carrier strip. The carrier sheet can include cut lines defining at
least a portion of the carrier strip. The carrier strip can be
removed from the label sheet assembly to expose at least a portion
of a layer of pressure sensitive adhesive on the labels. The label
sheet assembly has a uniform thickness in an area that includes the
carrier strip and the labels.
Inventors: |
Hong; Le H.; (San Gabriel,
CA) ; Novak; Michael; (Granby, MA) ; Hodsdon;
Jerry G.; (Forestdale, MA) ; Ramirez Villegas;
Gildardo; (Tijuana, MX) ; Veyna Hernandez; Alejandro
G.; (Tijuana, MX) ; Brisee; Florence M.;
(Waterford, NY) ; Ugolick; Ronald; (San Dimas,
CA) |
Correspondence
Address: |
AVERY DENNISON CORPORATION;Patent Group
Law Department - 3 South, P.O. BOX 7090
PASADENA
CA
91109-7090
US
|
Family ID: |
43414841 |
Appl. No.: |
12/617710 |
Filed: |
November 12, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11590409 |
Oct 31, 2006 |
|
|
|
12617710 |
|
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|
|
60799238 |
May 9, 2006 |
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Current U.S.
Class: |
283/81 ;
156/268 |
Current CPC
Class: |
B42P 2221/04 20130101;
Y10T 156/1082 20150115; G09F 3/02 20130101; B42F 21/00 20130101;
B42F 21/02 20130101; B42F 21/045 20130101 |
Class at
Publication: |
283/81 ;
156/268 |
International
Class: |
B42D 15/00 20060101
B42D015/00; B32B 38/04 20060101 B32B038/04 |
Claims
1. A label sheet assembly, comprising: a carrier sheet having first
and second sides; a facestock sheet releasably coupled to the first
side of the carrier sheet with a layer of pressure sensitive
adhesive; a liner sheet releasably coupled to the second side of
the carrier sheet with a layer of adhesive; cut lines in the
facestock sheet defining a set of labels; and cut lines in the
facestock sheet defining at least a portion of a carrier strip, the
carrier strip including a portion of the carrier sheet and a
portion of the facestock sheet; wherein: the carrier strip and the
labels are configured to be removed from the label sheet assembly
with the labels attached to the carrier strip; the labels are
configured to detach from a removed carrier strip when applied to a
substrate; and the label sheet assembly is configured to have a
uniform thickness in an area including the carrier strip and labels
before removal of the carrier strip and labels.
2. The label sheet assembly of claim 1, wherein the uniform
thickness is approximately 4.2 mils to approximately 12.6 mils.
3. The label sheet assembly of claim 1, wherein the uniform
thickness is approximately 6 mils to approximately 8.1 mils.
4. The label sheet assembly of claim 1, further comprising cut
lines in the carrier sheet defining at least a portion of the
carrier strip.
5. The label sheet assembly of claim 1, wherein the carrier sheet
is a non-adhesive coating.
6. The label sheet assembly of claim 5, wherein the carrier sheet
is pattern coated.
7. The label sheet assembly of claim 1, wherein: (i) the cut lines
in the facestock sheet defining a set of labels define a first set
of labels; (ii) the cut lines in the facestock sheet defining a
carrier strip define a first carrier strip; (iii) the label sheet
assembly further comprises: (a) additional cut lines in the
facestock sheet defining a second set of labels; (b) additional cut
lines in the facestock sheet defining a second carrier strip.
8. The label sheet of claim 1, further comprising: cuts in the
carrier sheet defining a backing strip; wherein: (i) the backing
strip is configured to be removed with the carrier strip and
labels; and (ii) the backing strip is configured to be removed from
the carrier strip and labels such that at least a portion of the
labels have an exposed layer of pressure sensitive adhesive.
9. The label sheet assembly of claim 1, wherein at least a portion
of the labels have an exposed layer of pressure sensitive adhesive
when the carrier strip and the labels are removed from the label
sheet assembly;
10. The label sheet assembly of claim 1, wherein the liner sheet is
free of cuts.
11. The label sheet assembly of claim 1, wherein the adhesive layer
coupling the liner sheet and the second side of the carrier sheet
is a dry-tack adhesive.
12. The label sheet assembly of claim 1, wherein the adhesive layer
coupling the liner sheet and the second side of the carrier sheet
is a heat seal layer.
13. The label sheet assembly of claim 1, wherein the adhesive layer
coupling the liner sheet and the second side of the carrier sheet
is an ultraremovable adhesive.
14. The label sheet assembly of claim 1, wherein the carrier sheet
includes a release layer.
15. The label sheet assembly of claim 1, where in the liner sheet
includes a release layer.
16. The label sheet assembly of claim 1, wherein the labels are
attached to the carrier strip with ties.
17. A method for making a label sheet assembly, the method
comprising: (i) providing facestock sheet material, carrier sheet
material, and liner sheet material; (ii) coupling the facestock
sheet material to a first side of the carrier sheet material with a
pressure sensitive adhesive; (iii) coupling the liner sheet
material to a second side of the carrier sheet material with an
adhesive; (iv) cutting lines in the facestock sheet material to
define a set of labels; and (v) cutting lines in the facestock
sheet material to define at least a portion of a carrier strip;
wherein: (i) the carrier strip includes a portion of the carrier
sheet material and a portion of the facestock sheet material; (ii)
the carrier strip and the labels are configured to be removed from
the label sheet assembly with the labels attached to the carrier
strip; (iii) the labels are configured to detach from a removed
carrier strip when applied to a substrate; and (iv) the label sheet
assembly is configured to have a uniform thickness in an area
including the carrier strip and labels before removal of the
carrier strip and labels.
18. The method of claim 17, the method further comprising: sheeting
a laminate material; wherein the step of coupling the facestock
sheet material to a first side of the carrier sheet material with a
pressure sensitive adhesive and the step of coupling the liner
sheet material to a second side of the carrier sheet material with
an adhesive form the laminate material.
19. The method of claim 18, wherein the laminate material includes
the facestock sheet material cuts.
20. The method of claim 17, wherein the uniform thickness is
approximately 6 mils to approximately 8.1 mils.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 11/590,409, filed Oct. 31, 2006, which claims
the benefit of U.S. Provisional Application No. 60/799,238, filed
May 9, 2006.
TECHNICAL FIELD
[0002] The present invention generally relates to labels and, more
particularly, relates to an improved label sheet assembly and a
method of making the improved label sheet assembly.
BACKGROUND
[0003] Various systems for indexing documents utilizing dividers
and labels are available. In a typical system, documents are
separated by divider sheets to aid with identification of the
documents. The dividers often include tabs having indicia thereon
for helping a user to locate and organize documents.
[0004] While such systems may have been satisfactory for helping to
index groups of documents, the task of applying identifying indicia
or identifying labels to the divider tabs is time consuming, clumsy
and subject to error. In many systems, tab attachable labels have
been employed to help overcome such difficulties. Typically, during
application the individual labels are separated from one another
and then attached individually to corresponding ones of the divider
tabs. In the course of individually applying the labels, they are
often not applied evenly, or properly aligned with the divider
sheet tabs. Even though the use of this type of attachable labels
may have permitted the divider tabs to have identifying indicia,
such labels have not been convenient to use.
[0005] Previous patents have taught various remedies for overcoming
these shortcomings when applying tabs to index dividers. One
previous example includes the use of precut labels attached to
carrier strips that are in turn secured to a backing sheet. The
precut labels are spaced apart on the carrier strips to align
substantially on the tabs on the divider sheets. The user can
separate a carrier strip and precut labels affixed thereto from the
backing sheet, place and align the carrier strip across the divider
sheet such that the precut labels are placed on the tabs of the
divider sheets. The carrier sheet is then pulled upwardly and away
from the divider sheet such that the precut labels separate from
the carrier strip and remain on the divider's tabs. This system,
while an improvement in certain respects over the prior art, has
the disadvantage that the strips are typically flimsy and difficult
to properly align. Additionally, the carrier strip can be sticky
and thus may stick to unwanted surfaces.
[0006] Another remedy for the shortcomings faced when applying tabs
to index dividers includes the use of a facestock adhered with
releasable adhesive to a liner sheet. Die cut lines are made
through the facestock to define labels to be aligned with either
one or more sets of dividers or sets of file folders. Different
pattern die cut lines are made through the liner sheet so that a
strip can be removed directly from behind the labels, exposing the
adhesive side of the labels. The labels are temporarily held onto
the remainder of the facestock by small ties. After alignment and
adhesion to the dividers, the facestock is then pulled upwardly and
away from the divider sheet. This movement breaks the ties, leaving
just the labels on the substrate. This system while a further
improvement requires the use of ties to maintain the labels during
alignment of the labels with the dividers. The ties may prove to be
a disadvantage in that they may leave rough edges about the
perimeter of the label where the ties have been broken during
removal of the label sheet.
[0007] Another shortcoming of previous patents is that after
removal of the strip and application of the labels onto the
substrate, the sheet is no longer printable. In one instance the
sheet is an irregular size after the strip is removed. Irregular
sheets may have difficulty passing through printers or copiers. In
another instance, after the labels have been applied to the
substrate, the sheet has holes where the labels were. The holes may
impart unwanted flexibility in the sheet or may provide catch
points causing difficulty in passing through a printer or copier.
Further removal of the labels and liner exposes adhesive on the
remainder of the sheet, which may cause the sheet to adhere to the
feed mechanism in a printer or copier. Thus, since printing after
label removal may be problematic; all the labels should be printed
in a single printing step. Any unprinted labels could not be
printed in a second pass through the printer or copier and would
have to be used unprinted or wasted.
[0008] Therefore it would be highly desirable to have a new and
improved label sheet assembly and method of making the label sheet
assembly to facilitate the application of tab labels in a fast,
efficient, and accurately aligned manner. Such a new and improved
label sheet assembly and method should enable a user to apply all
of the divider tab labels substantially simultaneously.
Furthermore, other desirable features and characteristics of the
present invention will become apparent from the subsequent detailed
description and the appended claims, taken in conjunction with the
accompanying drawings and the foregoing technical field and
background.
BRIEF SUMMARY
[0009] In an embodiment disclosed herein, a label sheet assembly
includes a carrier sheet, a facestock sheet, and a liner sheet. The
carrier sheet has first and second sides. The facestock sheet is
releasably coupled to the first side of the carrier sheet with a
layer of pressure sensitive adhesive. The liner sheet is releasably
coupled to the second side of the carrier sheet with a layer of
adhesive. Cut lines in the facestock sheet define a set of labels.
Cut lines in the facestock sheet define at least a portion of a
carrier strip. The carrier strip includes a portion of the carrier
sheet and a portion of the facestock sheet. The carrier strip and
the labels are configured to be removed from the label sheet
assembly with the labels attached to the carrier strip. The labels
are configured to detach from the removed carrier strip when
applied to a substrate. The label sheet assembly is configured to
have a uniform thickness in the area including the carrier strip
and the labels before removal of the carrier strip and labels.
[0010] In another embodiment disclosed herein, a method for making
a label sheet assembly includes the steps of providing facestock
sheet material, carrier sheet material, and liner sheet material,
coupling the facestock sheet material to the first side of the
liner carrier sheet material with a pressure sensitive adhesive,
coupling the liner sheet material to the second side of the carrier
sheet material with an adhesive, cutting lines in the facestock
sheet material to define a set of labels, and cutting lines in the
facestock sheet material to define at least a portion of a carrier
strip. The carrier strip includes a portion of the carrier sheet
material and a portion of the facestock sheet material. The carrier
strip and the labels are configured to be removed from the label
sheet assembly with the labels attached to the carrier strip. The
labels are configured to detach from the removed carrier strip when
applied to a substrate. The label sheet assembly is configured to
have a uniform thickness in the area including the carrier strip
and the labels before removal of the carrier strip and labels.
[0011] Other independent features and advantages of the improved
label sheet assembly and method will become apparent from the
following detailed description, taken in conjunction with the
accompanying drawings which illustrate, by way of example, the
principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will hereinafter be described in
conjunction with the following drawing figures, wherein like
numerals denote like elements, and
[0013] FIG. 1 is an enlarged cross-sectional view of a label sheet
assembly taken along line 1-1 of FIG. 3 according to an embodiment
of the present invention;
[0014] FIG. 2 is an enlarged cross-sectional view of a label sheet
assembly taken along line 2-2 of FIG. 3 according to an embodiment
of the present invention;
[0015] FIG. 3 is a front view of the label sheet assembly of FIGS.
1 and 2;
[0016] FIG. 4 is an enlarged view of a portion of a carrier strip
according to another embodiment of the present invention;
[0017] FIG. 5 is an enlarged view of a portion of a carrier strip
according to another embodiment of the present invention;
[0018] FIG. 6 is a perspective view showing of a first application
step by a user of a label assembly of FIG. 1;
[0019] FIG. 7 is a perspective view of a second application
step;
[0020] FIG. 8 is a perspective view of a third application
step;
[0021] FIG. 9 is a front view of a label sheet assembly according
to yet another embodiment of the present invention;
[0022] FIG. 10 is an enlarged cross-sectional view of a label sheet
assembly taken along line 10-10 of FIG. 11 according to another
embodiment of the present invention;
[0023] FIG. 11 is a front view of the label sheet assembly of FIG.
10;
[0024] FIG. 12 is an enlarged front view of an alternate label
sheet assembly according to another embodiment of the present
invention;
[0025] FIG. 13 is an enlarged cross-sectional view of a label sheet
assembly taken along line 13-13 of FIG. 14 according to yet another
embodiment of the present invention;
[0026] FIG. 14 is an enlarged front view of an alternate label
sheet assembly according to another embodiment of the present
invention;
[0027] FIG. 15 is an enlarged top view of a portion of the carrier
strip removed from the embodiment of FIGS. 13 and 14;
[0028] FIG. 16 is a simplified top view of an embodiment of an
alignment guide for use with the label sheet assembly of the
present invention;
[0029] FIG. 17 is a simplified top view of another embodiment of an
alignment guide for use with the label sheet assembly of the
present invention;
[0030] FIG. 18 is a simplified top view of another embodiment of an
alignment guide for use with the label sheet assembly of the
present invention;
[0031] FIG. 19 is a simplified perspective view of yet another
embodiment of an alignment guide for use with the label sheet
assembly of the present invention;
[0032] FIG. 20 is an enlarged sectional view of a laminate material
according to an embodiment of the present invention;
[0033] FIG. 21 is an enlarged sectional view of a laminate material
according to another embodiment of the present invention;
[0034] FIG. 22 is an enlarged sectional view of a laminate material
according to yet another embodiment of the present invention;
[0035] FIG. 23 is top plan view of a carrier sheet according to an
embodiment of the present invention;
[0036] FIG. 24 is top plan view of a carrier sheet according to
another embodiment of the present invention;
[0037] FIG. 25 is top plan view of a carrier sheet according to yet
another embodiment of the present invention;
[0038] FIG. 26 is top plan view of a carrier sheet according to yet
another embodiment of the present invention;
[0039] FIG. 27 is top plan view of a carrier sheet according to yet
another embodiment of the present invention;
[0040] FIG. 28 is top plan view of a label sheet assembly according
to an embodiment of the present invention;
[0041] FIG. 29 is top plan view of a label sheet assembly according
to another embodiment of the present invention;
[0042] FIG. 30 is top plan view of a label sheet assembly according
to yet another embodiment of the present invention;
[0043] FIG. 31 is top plan view of a facestock sheet according to
an embodiment of the present invention;
[0044] FIG. 32 is top plan view of a facestock sheet according to
another embodiment of the present invention;
[0045] FIG. 33 is top plan view of a facestock sheet according to
yet another embodiment of the present invention;
[0046] FIG. 34 is top plan view of a facestock sheet according to
yet another embodiment of the present invention;
[0047] FIG. 35 is top plan view of a label sheet assembly according
to an embodiment of the present invention;
[0048] FIG. 36 is an enlarged sectional view of the label sheet
assembly taken along line 36-36 of FIG. 35 according to an
embodiment of the present invention;
[0049] FIG. 37 is an enlarged sectional view of the label sheet
assembly taken along line 37-37 of FIG. 35 according to an
embodiment of the present invention;
[0050] FIG. 38 is an enlarged sectional view of the label sheet
assembly taken along line 38-38 of FIG. 35 according to an
embodiment of the present invention;
[0051] FIG. 39 is top plan view of the label sheet assembly of FIG.
35 illustrating a carrier strip and labels being removed according
to an embodiment of the present invention;
[0052] FIG. 40 is top plan view of the label sheet assembly of FIG.
35 after all carrier strips and labels are removed according to an
embodiment of the present invention;
[0053] FIG. 41 is an enlarged sectional view of the sheet of FIG.
40 taken along line 41-41 according to an embodiment of the present
invention;
[0054] FIG. 42 is top plan view of the label sheet assembly
illustrating a carrier strip and labels being removed according to
another embodiment of the present invention;
[0055] FIG. 43 is top plan view of the label sheet assembly
illustrating a carrier strip and labels being removed according to
yet another embodiment of the present invention;
[0056] FIG. 44 is an enlarged sectional view of a laminate material
being cut with a multi-step die according to an embodiment of the
present invention;
[0057] FIG. 45 is an enlarged sectional view of a laminate material
being cut with a single-step die according to an embodiment of the
present invention;
[0058] FIG. 46 is top plan view of a label sheet assembly according
to another embodiment of the present invention;
[0059] FIG. 47 is an enlarged sectional view label sheet assembly
according to an embodiment of the present invention;
[0060] FIG. 48 is top plan view of a portion of a label according
to an embodiment of the present invention;
[0061] FIG. 49 is top plan view of a portion of a label according
to another embodiment of the present invention;
[0062] FIG. 50 is top plan view of a portion of a label according
to yet another embodiment of the present invention;
[0063] FIG. 51 is top plan view of a portion of a label according
to yet another embodiment of the present invention;
[0064] FIG. 52 is a flowchart of an example method to produce a
label sheet assembly according to the invention;
[0065] FIG. 53 is a flowchart of another example method to produce
a label sheet assembly according to the invention;
[0066] FIG. 54 is a flowchart of yet another example method to
produce a label sheet assembly according to the invention;
[0067] FIG. 55 is a flowchart of yet another example method to
produce a label sheet assembly according to the invention; and
[0068] FIG. 56 is top plan view of the label sheet assembly
illustrating a carrier strip and labels being removed according to
yet another embodiment of the present invention.
DETAILED DESCRIPTION
[0069] The following detailed description is merely exemplary in
nature and is not intended to limit the invention or the
application and uses of the invention. Furthermore, there is no
intention to be bound by any expressed or implied theory presented
in the preceding technical field, background, brief summary or the
following detailed description.
[0070] In the following description, a label facestock is a sheet
that may be formed from various materials, and more particular a
printable sheet material, such as a paper or film, in which the
individual labels are formed that will readily adhere to index
divider surfaces. The label facestock may be multilayered and may
comprise laminated sheets. Further, the label facestock may also
include various coatings to impart surface characteristics such as
ink or toner receptivity, gloss, color, etc. A multilayered
laminated label sheet assembly at least initially includes at least
two components: the label facestock and a carrier sheet. In
addition, a liner sheet may be included in the assembly. An
adhesive is positioned between the label facestock and a silicone
release layer formed on an uppermost surface of the carrier sheet.
There is also included a second silicone release layer between the
carrier sheet and the liner when included. Each of the
subsequently-described label sheet assemblies may additionally
include a leader portion uniquely combined with a portion of the
label facestock to form a multilayered laminated label sheet
assembly capable of being fed through a copier or printer, such as
a laser jet printer, ink jet printer, or the like. As will become
apparent from the following detailed descriptions, the embodiments
herein allow the user to remove the entire line or row of labels
for simultaneously application to a line of stacked, staggered
index divider tabs in a manner that is an improvement over the
prior art. In other embodiments, partial rows or individual labels
may be removed.
[0071] Each of the cut lines described herein will typically
penetrate only one of the carrier sheet or the label facestock
sheet. The cut portions of the label facestock are maintained on
the sheet assembly by an adhesive so that they will not separate
from the sheet assembly while being passed through a printer or
copier.
[0072] FIGS. 1-8 depict an embodiment of a label sheet assembly
according to the present invention, showing die cut configurations
for index divider labels. More specifically, referring to FIGS.
1-3, illustrated are cross-section views and a front view of the
label sheet assembly according to the present invention. FIGS. 4
and 5 illustrate alternative carrier strip geometries and FIGS. 6-8
illustrate steps in the method of applying the labels to index
dividers according to the present invention. Referring now to FIGS.
1 and 2, illustrated is a portion of a label sheet assembly 10
comprised of multiple layers 12. FIG. 1 illustrates a sectional
view taken through line 1-1 of FIG. 3, and FIG. 2 illustrates a
sectional view taken along 2-2 of FIG. 3. As depicted in FIGS. 1
and 2, the label sheet assembly 10 includes a label facestock 14, a
liner 16, and a carrier strip 18 sandwiched therebetween. The label
facestock 14 is defined by a first side 21 and an opposed second
side 22. In this particular embodiment, label facestock 14 has an
ink or laser receptive printable surface on first side 21. There is
formed between the carrier strip 18 and the label facestock 14, an
adhesive layer 24 positioned on the second side 22 of the label
facestock 14. Adhesive layer 24 releasably adheres the label
facestock 14 to the carrier sheet 18. A silicon release layer 26 is
optionally included on a carrier strip upper surface 27 between the
carrier strip 18 and the facestock 14. It should be understood that
the silicon release layer 26 is optional in an embodiment including
a removable or ultraremovable adhesive as the adhesive layer 24. In
addition, a silicone release layer 28 is sandwiched between the
carrier strip 18 and the liner 16.
[0073] Referring now to FIG. 3, the label facestock 14 includes a
plurality of cuts 30 that extend through the label facestock 14 (as
best seen in FIGS. 1 and 2) and define a perimeter of one or more
labels 32, or portions of labels. In this particular embodiment the
label facestock sheet 14 is cut by the cut lines 30 into five
columns of four rows of labels. The plurality of cuts 30 are
preferably formed using a rotary die cutter or cutters that are
capable of cutting and scoring soft to semi-rigid material by
forcing it between the blades on a cylindrical die and a hard
cylindrical anvil, but in the alternative can be formed by a
slicing process, such as done with a sign cutter. In a preferred
embodiment, the cut lines 30 are continuous die cut. In an
alternate embodiment, the cut lines 30 may comprise die cuts in the
areas forming the labels 32 and may comprise other weakened lines,
such as perforations, in areas not forming the labels 32.
[0074] In the embodiment illustrated in FIGS. 1-3, included is a
plurality of labels 32 for placement on a plurality of staggered
tabs of a set of index dividers. It should be understood that while
a specific configuration of the labels 32 is depicted, any one of
numerous label configurations is anticipated by this disclosure
dependent upon end use. Accordingly, different numbers of columns
and rows or different patterns (non-matrix) of the labels can be
formed as needed. In addition, as illustrated in FIG. 3, the
carrier strip 18 includes a plurality of edges 34 and may further
include additional weakened lines 35 that allow the sheet assembly
10 to separate into two or more smaller strips. The weakened lines
35 are formed through both the label facestock 14 and the carrier
strips 18 to allow for separation. The smaller strips allow the
user to select and remove a subset of the labels 32.
[0075] Referring again to FIG. 3, a portion of the plurality of
edges 34 extends from an outermost region 36 of assembly 10 a
distance, and then extend down, across and up, parallel to a
portion of an outer shape or perimeter of an adjacent label 32 but
spaced inwardly a slight distance therefrom and extending out to
form a small plateau 37 between adjacent labels 32 similar to the
spacing on the label facestock 14 between the adjacent labels 32.
It should be appreciated that during the fabrication of sheet
assembly 10, the carrier strips 18 may be formed to extend
completely across the sheet assembly 10 or in the alternative do
not extend completely across the sheet assembly 10. A portion of
the carrier strip edge 34 as stated is spaced inwardly a slight
distance from a portion of the perimeter of the labels 32. This
allows a portion of the carrier strip 18 to overlap the die cuts 30
formed in the label facestock 14 and defining labels 32. This
overlap area 38 is preferably less than approximately 20% of the
area of label 32. Although, an overlap that exceeds approximately
20% of the area of label 32 could be implemented. It will be
appreciated that this amount of overlap could make it difficult to
remove the carrier strip 18 after the labels 32 have been applied
to the tabs of the index dividers (discussed presently). Moreover,
the overlap 38 will vary depending, for example, on the type of
adhesive that may be used. For example, adhesives ranging from
permanent to ultraremovable may be used for adhesive layer 24. For
embodiments in which an aggressive, permanent adhesive is used for
adhesive layer 24, the minimum overlap area 38 will be relatively
small, as compared to embodiments in which a removable adhesive is
used. Thus, while the specific amount of overlap 38 may vary, it
will be appreciated that the overlap 38 should be sufficiently
large to hold the labels 32 during handling, but sufficiently small
to allow clean removal of the carrier strip 18 from the label 32
after application (described presently).
[0076] Referring now to FIGS. 4 and 5, illustrated are top views of
a portion of the carrier strip 18 having been removed from the
liner 16 in which alternative overlap geometries are illustrated.
More specifically, illustrated in FIG. 4 is an embodiment in which
the carrier strip edge 34 substantially evenly divides label 32 and
extends generally from a first corner 39 to a second opposed corner
41. FIG. 5 illustrates an embodiment in which the carrier strip
edge 34 is formed having a waved or bumped geometry. In both
alternative embodiments illustrated, the carrier strip edge 34 does
not follow the general shape of the label 32 as previously
described with regard to FIG. 3, yet allows sufficient overlap
between the carrier strip 18 and the facestock 14, and more
particularly label 32, to: (i) hold the labels 32 during handling,
(ii) allow for clean removal of the carrier strip 18 after
application, (iii) facilitate the adhering of the label 32 to the
surface of the dividers, etc., and (iv) provide for efficient
manufacturability.
[0077] Referring again to FIG. 3, both the carrier strip 18 and the
label facestock 14 preferably have additional cut lines. As can be
understood from FIG. 3, portions of the label facestock 14 have
been cut and stripped away to form the edge margins 40 of the sheet
assembly 10. In addition, any portion of the carrier strip 18
formed in this area has also been stripped away. These margins 40
are provided to optimize printer and copier performance of the
label sheet assembly 10. Additionally, an optional gutter strip 42
has been cut and removed from the center and a perforation line 44
formed down the center of the label facestock 14. This allows the
construction to be divided into two parts by the user. It should be
appreciated that other forms of weakened lines may be used in place
of the perforation line 44 to divide the sheet assembly 10. Two
smaller label applicator construction sheet assemblies are thereby
formed for passing through a printer or as may be desired by the
user.
[0078] After passing through a printer or copier, and with desired
indicia 50 printed on the labels 32, the labels 32 are ready to be
adhered to the tabs of an index divider, folder, or the like.
Referring now to FIGS. 6-8, illustrated are perspective views of a
top portion of the label sheet assembly 10 according to FIGS. 1-3,
showing a plurality of steps for applying a first series of printed
labels 32. As illustrated in FIG. 6, initially the carrier strip
18, including a portion 52 of the label facestock 14 of the sheet
assembly 10 is pulled away and separated from a remainder portion
54 of the sheet assembly 10. It should be appreciated that although
illustrated as being pulled from a specific direction relative to
the edges of the sheet assembly 10, the carrier strip 18 may be
formed to be pulled from either direction adjacent an edge of the
sheet assembly 10, or both. During this step, the labels 32 are
removed from the full liner sheet 16 when the user detaches the
carrier strip 18 from the full liner sheet 16, exposing the
adhesive side 24 of the labels 32. At this point a portion of each
label 32 overlaps with the carrier strip 18 and is adhesively held
onto the carrier strip 18 by the adhesive connection between the
label facestock 14 and the carrier strip 18. This overlap of the
labels 32 with the carrier strip 18 negates the need for other
means of tying the labels 32 together at this stage. It should be
noted that the carrier strip edges 34 follow both the horizontal
and vertical cuts 30 of the label 32, thereby providing support on
at least a portion of three sides of the label 32. As a result, the
carrier strip 18 provides a strong, not flexible or flimsy, means
for manipulating and accurately positioning a row of exposed labels
32 onto the desired positions of a plurality of staggered tabs 56
of a plurality of index dividers 58 as shown in FIGS. 7 and 8.
[0079] Holding the carrier strip 18 with the labels 32 having their
adhesive sides exposed, the user then aligns the labels 32 with the
tabs 56 of the index dividers 58. Each of the properly positioned
labels 32 is then pressed flat down to form a strong adhesive bond
onto the respective tabs 56 as depicted in FIG. 7. The carrier
strip 18 to which the labels 32 are less strongly adhesively
attached is then pulled away from the adhered labels 32, leaving
just the labels 32 on the tabs 56 as illustrated in FIG. 8. In that
the carrier strip 18 has been removed from the liner 16 having the
labels adhesively attached thereto, the liner 16 remains the
original size and is described as multipassable. To prepare more
labels 32 for new tabs if additional labels were not previously
printed, the user simply reruns the multipassable label sheet
assembly 10 through the printer, printing on the subsequent array
of labels to produce aligned, printed tab labels. It should be
understood that the user can print as many labels as needed during
a single printing process. Referring back to FIG. 6, after
printing, a next carrier strip 53 may be removed from the liner
sheet 16 to expose the backsides of the second line of printed
labels 32. The second line of printed labels 32 is then manipulated
into position on a second set of staggered dividers (not shown),
the labels 32 pressed into position and the carrier strip removed.
This can be understood by again viewing FIGS. 6 through 8.
[0080] As best illustrated in FIG. 8, during adherence of the
labels 32 to the tabs 56, for a brief moment a portion of the
carrier strip 18 is positioned between the divider tab 56 and the
label 32. The user after pressing the label 32 against the divider
tab 56 adheres a major portion of the label 32 to the divider tab
56 and a small edge portion 33 is attached to the carrier strip 18.
The carrier strip 18 is then pulled past the labels 32 so that the
label edges 33 bend or flex slightly to allow the carrier strip 18
to be removed. The label 32 exhibits sufficient tension and memory
in its material to cause the edges 33 that are lifted up during
removal of the carrier strip 18 to snap back onto the divider tab
56. The user may then smooth the edges to ensure complete
adhesion.
[0081] Referring now to FIG. 9, illustrated is an embodiment of a
sheet assembly 50 formed in generally the same manner as the sheet
assembly 10 described in FIGS. 1-3. In this particular embodiment,
a single label 52 is formed on a carrier strip 54 to allow for
removal and positioning of a single label 52. Each label 52 may be
printed and peeled away from a liner for individual placement. It
should be understood that the label 52 size and placement can vary
depending upon the specific application for the label 52.
[0082] Referring now to FIGS. 10-12, illustrated is another
embodiment of a label sheet assembly 60 including a plurality of
labels 65. FIG. 10 is a cross-section view taken through line 10-10
of FIG. 11. Similar to the embodiment illustrated in FIGS. 1-3, the
label sheet assembly 60 is formed of multiple layers 62 that
include a label facestock 64 adhered with an adhesive 67 to a
carrier sheet 68. The carrier sheet may optionally include a
silicone release layer 69, such as that described in FIG. 1 when
adhesive 67 is not formed from an easily removable adhesive. The
carrier sheet 68 is adhered with a heat activated coating 70 to a
sheet 72, either a paper or a film. The heat activated coating 70
may be formed of a material such as polyolefin in a homogenous
mixture or as a single component composition. In addition, heat
activated coating 70 may be formed of a copolyester, ethylene vinyl
acetate, ethylene vinyl alcohol, polyvinyl chloride, ionomer
resins, ethylene methyl acrylate, ethylene ethyl acrylate, ethylene
acrylic acid, or the like. Heat activated coating 70 and sheet 72
together form a liner sheet 73. Alternatively, the heat activated
coating may be replaced with a removable adhesive, ultraremovable
adhesive or pattern-coated adhesive, and thereby also not require a
silicone release layer. Similar to the first embodiment, it should
be understood that label facestock 64 includes a printable surface
76. The printable surface 76 may include surface treatments or
coatings to enhance acceptance of indicia.
[0083] Referring more specifically to FIGS. 10 and 11, the label
facestock 64 includes a plurality of cuts lines 74 that extend
through the label facestock 64 and define the perimeter of one or
more labels 65 or portions of labels. In this particular embodiment
and similar to the first embodiment, different numbers of columns
and rows or different patterns (non-matrix) of the labels or
carrier strip may be formed as needed. In addition, the carrier
sheet 68 includes a plurality of cuts lines 78 that extend through
the carrier sheet 68 and define a plurality of cut edges 69 of at
least one carrier strip 71. More specifically, as illustrated in
FIG. 11, cut lines 74 that define the label 65 having an uppermost
edge 66 that is straight across and in line with a cut line 78 in
the carrier sheet, defining a top edge 69 of the carrier strip. The
cuts lines 78 in the carrier sheet 68 further define a plurality of
cut edges 73 in the carrier strip 71, wherein a small portion of
the resulting carrier strip 71 covers a portion of each label 65
and a portion between the labels. This differential yields an
overlap region that surrounds the perimeter of the label 65 and
functions similar to the overlap region in the first embodiment,
namely to lift up the array of labels 65 when the user separates
the carrier strip 71 from the liner sheet 73.
[0084] Referring now to FIG. 12, illustrated is an alternate
embodiment in which cut lines 74 define the label 65 in a central
portion of the carrier strip. Cut lines 78 in the carrier sheet
define the top edge 69 of the carrier strip 71 that forms a
straight edge across the sheet assembly 60. Similar to the
embodiment illustrated in FIG. 11, the cuts lines 78 in the carrier
sheet 68 further define a plurality of cut edges 73 in the carrier
strip 71, wherein a small portion of the resulting carrier strip 71
covers a portion of each label 65 and a portion between the labels.
This differential yields an overlap region that surrounds the
perimeter of the label 65 and functions similar to the overlap
region in the first embodiment, namely to lift up the array of
labels 65 when the user separates the carrier strip 71 from the
liner sheet 73. In the embodiments illustrated in FIGS. 11 and 12,
sheet assembly 60 includes the liner sheet 73, including heat
activated coating 70 and sheet 72, the carrier sheet 68, and the
label facestock sheet 64 to form a laminate construction that is
adapted to pass through a printer or copier multiple times in that
the liner sheet is not cut and remains the same size. Desired
indicia are printed on the labels 65 before the carrier strip 71 is
removed to a separated position.
[0085] During application of the labels 65 illustrated in FIGS. 11
and 12 to a plurality of tabs on index dividers, folders, or the
like, the carrier strip 71 is detached from the liner sheet 73 in a
manner similar to that previously described with regard to the
first embodiment. A portion 80 of the carrier strip 71 that covers
the adhesive layer 67 where the plurality of labels 65 have been
defined is left behind because it is attached to the heat sealable
layer 72. This defines a window area (not shown) in the carrier
strip 71 and allows the adhesive on labels 65 to be exposed and,
ready for application onto the aligned tabs. The user then proceeds
like described with regard to FIGS. 6-8 to use the carrier strip 71
to align the array of labels 65 with the tabs of the dividers, file
folders, or the like. After proper alignment, the user then applies
the array of labels 65 and removes the carrier strip 71, leaving
the labels 65 on the tabs. To prepare more labels 65 for new tabs,
the user simply reruns the multipassable label sheet assembly 60
through the printer, printing on the subsequent array of labels to
produce aligned, printed tab labels. It should be understood that
the user can print as many labels as needed during a single
printing process.
[0086] Referring now to FIGS. 13-15, illustrated are a
cross-section view taken through line 13-13 of FIG. 14, a front
view of the label sheet assembly, and a front view of a portion of
a carrier sheet according to the present invention. Similar to the
embodiment illustrated in FIGS. 1-3, the label sheet assembly 90 is
formed of multiple layers 92 that include a label facestock 94
adhered with an adhesive 96 to a carrier sheet 98. It should be
understood that carrier sheet 98 may optionally include a silicone
release layer 99 as described in the previous embodiments. The
carrier sheet 98 when cut serves a similar function as both the
carrier strip and liner in the previous embodiments. Similar to the
first and second embodiments, label facestock 94 includes a
printable surface 95.
[0087] The label facestock 94 includes a plurality of cuts 100 that
extend through the label facestock 94 and define a perimeter of one
or more labels 102 or portions of labels. In this particular
embodiment and similar to the first embodiment, different numbers
of columns and rows or different patterns (non-matrix) of the
labels can be formed as needed. The carrier sheet 98 includes a
plurality of cuts 104 that extend through the carrier sheet 98 and
define a plurality of edges of a carrier strip 101. As in the
previous embodiments, cuts 104 are positioned slightly inward of
cuts 100 about at least a portion of the label 102, so that the
carrier sheet 98, and more particularly the carrier strip 101,
overlaps the labels 102 about at least a portion of the perimeter,
thereby defining an overlap.
[0088] During application of the labels 102 to a plurality of tabs
on index dividers, folders, or the like, a first carrier strip 101
is removed from the sheet assembly 90, thereby reducing the overall
sheet assembly size. A plurality of portions 105 of the carrier
strip 101 are removed to expose the adhesive backing on labels 102.
The portions 105 may be removed individually, or may be removed in
a strip, as best illustrated in FIG. 15. Portions 105 have been cut
to allow for a portion 106 of the carrier sheet 98 to remain and
tie together the plurality of portions 105 upon removal to expose
the adhesive backing on labels 102. The user then proceeds as
described with regard to FIGS. 6-8 to use the carrier strip 101 in
a similar manner as the previous embodiments of the carrier strip;
to align the array of labels 102 with a plurality of tabs of
dividers, file folders, or the like. After proper alignment, the
user applies pressure to the array of labels 102 and removes the
carrier strip 101, leaving the labels 102 on the tabs. In this
particular embodiment sheet assembly 90 includes the carrier sheet
98 and the label facestock sheet 94 to form a laminate construction
that is adapted to pass through a printer or copier. In that the
carrier sheet 98 is cut into a plurality of carrier strips 101 and
subsequently each is detached or separated from the plurality of
carrier strips 101, and removed, the sheet assembly 90 is reduced
in size and only passable through a printer or copier a single
time. An alternate embodiment may include a gutter, similar to a
previous embodiment, in which each separate half of the sheet
assembly may be passed through a printer or copier a single time.
Desired indicia are printed on the labels 102 before the carrier
strip 101 is removed to a separated position.
[0089] Referring now to FIGS. 16-19, to minimize movement or
shifting of a set of index dividers, file folders, or the like
during the label application process, methods for temporarily
aligning the set of index dividers are presented. As illustrated in
FIGS. 16-19, provided is a set of index dividers 110, including a
plurality of tabs 112 having a generally centralized portion 114
for placement of a label according to the present invention
including identifying indicia. To provide proper alignment of the
labels on tabs 112, the dividers 110 can be held in place by a
single length or plurality of lengths, of removable tape 116
positioned across a lower portion 118 of the tabs 112 outside of
the portion 114 where the labels will be adhered as illustrated in
FIG. 16. In the alternative, a single length of a tape 116 or a
plurality of lengths of tape 116 may be positioned across an edge
115, or multiple edges, of the set of index dividers 110 as best
illustrated in FIG. 17 or across a binding edge 117 of the dividers
110 as best illustrated in FIG. 18. The tape 116 can be in the form
of either a complete strip or a plurality of sections that are
spaced apart, covering the entire length or width of the divider
set 110 as illustrated. After the labels have been applied onto the
tabs 112, the tape 116 is removed using an optional pull tab 119 as
illustrated in FIG. 18 or by simply lifting and removing the tape
16 from the dividers 110. Alternatively, a glue or adhesive that
does not leave undesired residue on the edges of the dividers 110
can be used in place of the tape 116.
[0090] Another method for aligning and securing sets of dividers
during application of the labels according to the present invention
uses an alignment guide as illustrated in FIG. 19. More
specifically, provided is an alignment guide 120 comprising at
least one post 122 positioned on an alignment strip 124 in a manner
that would align with the rings in a typical binder in which a set
of dividers 128 may be placed. In one embodiment, a series of at
least two holes 126 are formed in the dividers 128 having a
plurality of staggered tabs 130 to which a label is to be adhered.
The at least one post 122 is smaller in dimensions than the holes
126 on the dividers 128, thereby allowing the at least one post 122
to fit through the holes 126. To position the dividers 128 for
label application, a user places the dividers 128 onto the
alignment guide 110, and more particularly places the at least one
post 122 through the divider holes 126, making sure to align all
the dividers holes 126 with at least one post 122. This ensures
that the tabs 130 for each divider 128 will be aligned with the tab
130 on adjacent dividers 128 and that the set of dividers 128 will
not shift during the label application process. The at least one
post 122 can be manufactured using thermoforming, injection
molding, profile extrusion, or other methods known to the
industries. In addition, an optional flap 136 may be incorporated
with the alignment strip 124 to allow for folding over, as
illustrated at 134, at least one of the edges 132 of the set of
dividers 128. It can be appreciated that posts, flaps, or
combinations of posts and flaps can be used as an alignment means.
Alternative means for aligning the set of index dividers 128 of the
present invention are also anticipated herein, for example, a pouch
such as that taught in U.S. Pat. No. 6,803,084, assigned to the
same assignee, and incorporated herein by this reference.
[0091] Embodiments shown in FIGS. 1-6 include carrier strips
separated from one another by a gap wider than the width of a
separation line. Additional embodiments of the invention include
using a carrier sheet cut into strips separated from one another by
a separation line between them. As used in discussion of the
embodiments that follow, the term laminate or laminate material
refers to a laminated construction prior to the formation of any
cuts therein. The term label sheet assembly refers to a laminated
construction after formation of cuts therein.
[0092] In one embodiment 150, as shown in FIG. 20, the laminate 152
includes a facestock sheet 154, a carrier sheet 156, and a liner
sheet 158. The facestock sheet is releasably attached to one side
160 of the carrier sheet with a layer of pressure sensitive
adhesive 162. The liner sheet is releasably attached to the other
side 164 of the carrier sheet with an adhesive 166 that can also be
a pressure sensitive adhesive.
[0093] The facestock sheet 154 can be made of any material suitable
for use as a pressure sensitive label. Suitable materials include,
for example, films, papers, and laminates of film and paper.
Polyesters, polyolefins, polyvinyl chlorides, other heat-stable
films, and top-coated papers and films are non-limiting examples of
materials suitable for use as label facestocks. Topcoats useful for
use with facestock sheets include those known to promote ink and
toner receptivity.
[0094] The liner sheet 158 can be made from, for example,
super-calendered paper, polyolefin coated paper, lacquer-coated
paper, varnish-coated paper, and heat-stable films. Useful
super-calendered papers include those in the Felix Schoeller
(Osnabrueck, Germany) Matte Coated Paper product line. Useful
polyolefin-coated papers include those in the Felix Schoeller
Glossy Coated Paper product line. The liner sheet can be sealed, if
necessary, to prevent or reduce penetration of the adhesive 166
that adheres the carrier sheet 156, thus permitting the carrier
sheet to be removed from the liner sheet. An example of a useful
sealant is CRAIGCOAT 1091X (Craig Adhesives and Coatings, Newark,
N.J.). Alternatively, if the liner sheet is sufficiently
impermeable to the adhesive, for example, if the liner sheet is
polyolefin-coated paper, no sealant is needed.
[0095] The carrier sheet 156 can be made of materials that are
typically suitable for backing pressure sensitive labels. The
carrier sheet can be coated with a silicone release material 168,
or other material suitable as release material for pressure
sensitive adhesives. Suitable carrier sheet materials include, for
example, super-calendered kraft paper, glassine paper, polyesters,
polyolefins, heat-stabilized polyolefins, and machine-finished
coated paper.
[0096] The pressure sensitive adhesive layer 162 between the
facestock sheet 154 and the carrier sheet 156 can be formed from
any pressure sensitive adhesive known in the art. The pressure
sensitive adhesive is chosen based upon the desired label
properties, for example, a removable or ultraremovable adhesive can
be used if the label is desired to be cleanly removed from the
substrate to which it is attached. Alternatively, a permanent
pressure sensitive adhesive can be used if the label is to
permanently adhere to the substrate. Suitable pressure sensitive
adhesives include those based upon acrylics, rubbers, and
silicones. The pressure sensitive adhesive can be solvent-based,
water- or emulsion-based, suspension-based, and hot-melt or 100%
solids-based. A wide range of tackifiers known in the art can be
used to modify the properties of the pressure sensitive
adhesive.
[0097] The adhesive layer 166 between the carrier sheet 156 and the
liner sheet 158 can be formed with a material that can be
characterized as a dry-tack or fugitive adhesive. These adhesives
provide a non-destructive bond between the carrier sheet and the
liner sheet and result in tack-free surfaces after debonding.
Dry-tack adhesives include, for example, natural rubber latex,
polyvinyl acetate, emulsion acrylics, and thermoplastic elastomers.
An example fugitive adhesive useful in this embodiment is NWC 2000C
DRY RELEASE ADHESIVE (Ashland, Inc., Covington, Ky.).
Alternatively, a removable or ultraremovable pressure sensitive
adhesive can be used. When a removable or ultraremovable pressure
sensitive adhesive is used, the adhesive can remain on the liner
sheet after debonding of the carrier sheet from the liner sheet,
resulting in the exposed carrier sheet surface being tack-free.
[0098] The thickness of the entire laminate 152 is typically from
approximately 6 mils and approximately 8.1 mils, although values
outside this range can be used as long as a label sheet assembly
made from the laminate is capable of passing through a printer or
copier. The thickness of the facestock sheet 154 is typically from
approximately 1 mil and approximately 3.5 mils, the thickness of
the carrier sheet 156 is typically from approximately 0.5 mil and
approximately 2.6 mils, and the liner sheet 158 thickness is
typically from approximately 2 mils to approximately 4 mils. The
thickness of the pressure sensitive adhesive layer 162 is between
the facestock sheet and the carrier sheet is typically from
approximately 0.5 mil to approximately 1.5 mils, depending on the
adhesive used and the physical properties desired. The adhesive
layer 166 between the carrier sheet and the liner sheet is
typically from approximately 0.2 mil and approximately 1 mil. The
total thickness of the laminate includes the thickness of the
facestock sheet, the thickness of the carrier sheet, the thickness
of the liner sheet, the thickness of the layer of pressure
sensitive adhesive, and the thickness of the layer of the adhesive
layer.
[0099] An example of laminate material 152 useful for use in the
embodiment of FIG. 20 is VERSATILE COUPON TC (Avery Dennison, Inc.,
Pasadena, Calif.)
[0100] Another embodiment 170 is shown in cross-section in FIG. 21.
In this particular embodiment, the adhesive layer 166 between the
carrier sheet 156 and the liner sheet 158 is replaced with a
heat-seal layer 172. The heat-seal layer serves to hold the carrier
sheet and the liner sheet together, much the same way as the
adhesive that is being replaced. The heat seal layer includes a
heat sealable material, an example of which is ethylene vinyl
acetate. Other heat sealable materials include, for example, ethyl
methacrylate, ethylene co-acrylic acid, low density polyethylene,
high density polyethylene, SURLYN (E.I. du Pont de Nemours and
Company, Wilmington, Del.), and mixtures thereof.
[0101] Yet another embodiment 174 shown in cross-section is
illustrated in FIG. 22. In this particular embodiment, the carrier
sheet 156 is replaced by a non-adhesive coating 176 between the
pressure sensitive adhesive layer 162 and a release layer 178
applied to the liner sheet 158. The coating is printed or pattern
coated to cover areas of the pressure sensitive adhesive forming
part of a carrier strip that will be described herein below,
thereby rendering the pressure sensitive adhesive non-tacky. An
exemplary coating includes a mixture of 8.7 parts of polyvinyl
acetate having glass transition temperature greater than 25.degree.
C. (e.g., VINAC XX-210, Air Products and Chemicals, inc.,
Allentown, Pa.) to 1 part of polystyrene emulsion (e.g., ACRYGEN
4999, Omnova Solutions, Inc., Chester, S.C.). Other useful coatings
include, for example, styrene acrylates, polyurethanes,
polyacrylates, and cured water-borne epoxy resins.
[0102] FIGS. 23-27 illustrate cut lines in the carrier sheet 156
that form the carrier strip, or part of the carrier strip. The cut
lines are die cut lines through the carrier sheet, although, other
types of cuts, for example, perforations and cuts and ties, can be
used instead. One method 512 of making the cut lines is to laminate
the carrier sheet to the liner sheet 158 with adhesive 166, as
shown at 516 in FIG. 52. The cut lines are then cut through the
carrier sheet, but not through the liner sheet as shown at 518 in
FIG. 52. In an alternative method 526 of making the cut lines, as
shown in FIG. 53, the carrier sheet is laminated to the facestock
sheet 154 with pressure sensitive adhesive 162, as shown at 530 in
FIG. 53. The cut lines are then cut through the carrier sheet, but
not through the facestock sheet at 534. In yet other alternative
methods, cuts in the carrier sheet or facestock sheet are made
prior to lamination, for example, step 520 in FIG. 52. If the cuts
are made prior to lamination, continuous die cuts can be used to
produce carrier sheets as shown in FIGS. 24-27. However, the
carrier sheet in FIG. 23 and the facestock sheets shown in FIGS. 31
and 32 include areas surrounded by cut lines. Perforated lines,
cuts and ties, or other types of lines which facilitate the cut-out
portion remaining attached to the carrier sheet, can be used for
sheets with areas surrounded by cut lines.
[0103] Turning now to FIG. 23, a carrier sheet 180 is shown, for
example, an 8.5 inches.times.11 inches carrier sheet. The sheet has
top 182, bottom edges 184, and side edges 186. There are several
cut lines in the carrier sheet that define a part of a carrier
strip 188 and cut-out portions 190. The cut-out portions lie behind
labels 252 cut in the facestock sheet 254, in FIG. 28, and are at
least partially overlaid by the labels in the final label sheet
assembly 256. There is a cut line 192 running most of the length of
the carrier sheet corresponding to a bottom edge 194 of the carrier
strip and cut lines 196 parallel to the sheet side edges defining
side edges 198 of the carrier strip. Cut lines 200 between the side
edge of the carrier strip and the end cut-out portions 202 define
an end edge 204 of the carrier strip. The cut lines forming the end
edges of the carrier strip and the cut lines 206 between the
cut-out portions define a part of the top edge 208 of the carrier
strip. A curved cut line 210, that also defines the bottom edge 212
of the cut-out portion, defines the remainder of the top edge of
the carrier strip. A part of the curved cut line 258 will underlie
a label in the label assembly sheet and another part of the curved
line 260 will underlie the facestock sheet outside of the label.
The top edge 214 of the cut-out portion is defined by a cut line
216 that corresponds to the top edge of the label in the facestock
sheet. While the shape of the cut-out portion is shown as including
a linear cut along the top edge and a curved cut along the bottom
edge, other shapes can be used. For example, the cut-out portion
can be similar in shape to an overlying label.
[0104] When the carrier strip is subsequently removed from the
label sheet assembly, for example, see FIG. 39, the cut-out
portions remain attached to the liner sheet. This is accomplished
through appropriate choice of adhesives and release systems, in
which case the adhesion between the carrier sheet and the liner
sheet should be greater than the adhesion between the carrier sheet
and the facestock sheet.
[0105] An alternative embodiment 218 is shown in FIG. 24. In this
embodiment, the cut lines along bottom and side edges, 194 and 196
in FIG. 23, of the carrier strip 188 are not formed in the carrier
sheet 218 at the same time as the top edge 220. The bottom and side
edges of the carrier strip will be formed later with a single cut
through the facestock sheet 154 and the carrier sheet, rather than
a single cut in each of the carrier sheet and the facestock sheet
that are aligned and coincident. Similar to the embodiment shown in
FIG. 23, the top edge of the carrier strip is formed by curved cut
lines 222 that will at least partially underlie labels 252, for
example, see FIG. 28, cut in the facestock sheet in the final label
sheet assembly 256, and by curved cut lines 224 between the
label-overlaid curved cut lines. The end edge 226 of the carrier
strip cut in the carrier sheet intersect the side edges 198, in
FIG. 23, that subsequently will be cut through the facestock sheet
and the carrier sheet.
[0106] The alternative embodiment 228 shown in FIG. 25 is similar
to the embodiment shown in FIG. 24. Instead of the curved cut lines
224 between the label-overlaid curved cut lines 222, the lines 230
in FIG. 25 are linear.
[0107] Embodiments 180, 218, and 228 shown thus far have areas in
the carrier sheet 156 that will underlie five labels 348 cut into
the facestock sheet 154, for example, see FIG. 35. The embodiment
232 shown in FIG. 26 shows sets of cut lines in the carrier sheet
156 that will underlie three labels 264, see FIG. 29, cut into the
facestock sheet 266. These labels are longer than those shown in
FIGS. 23-25. When the carrier strip 268 is removed from the final
label sheet assembly 262, longer labels may sag and become
difficult to apply. Thus, the curved cut lines 234 that underlie
labels cut in the facestock sheet can bow upward, forming another
area 236 that underlies the facestock sheet label. This additional
underlying area supports the middle portion of the label, thus
reducing the label's ability to sag.
[0108] Yet another embodiment 238 of a carrier sheet with cuts that
form the top edge 240 of a carrier strip is shown in FIG. 27. The
curved cut lines 242, see FIG. 30, that underlie the labels 270 cut
in the facestock sheet 272 are shaped to follow the edge 274 of the
label. This curved cut line in the carrier sheet is positioned such
that a thin area 244 along the entire edge underlies the label,
thereby holding the label in place when the carrier strip is
removed. The curved cut lines 246 between the label-overlaid cut
lines 242 include flattened portions 248. Both end edges 250 of the
carrier strip are linear, and will intersect a cut line 276 that
will be formed through the facestock sheet and the carrier
sheet.
[0109] Turning now to the facestock sheets, example cut line
patterns are shown in FIGS. 31-34. The cut lines in the facestock
sheet 278 form an upper portion 284 of the carrier strip 280 and a
set of labels 282 attached to the carrier strip. FIG. 31 shows an
embodiment of facestock sheet cut lines. All the cut lines in FIG.
31 are through the facestock sheet, but not through the carrier
sheet 156. The labels are shown with rounded corners 286, although
other shapes, e.g., square-cornered labels, can be used. Between
the labels 288 and at the end edges 290 of the carrier strip are
linear cuts that intersect the label cut 292 such that there is a
continuous cut line between all the labels. These cuts divide the
label cuts into a top label cut 294 and a bottom label cut 296.
There are additional cut lines in the facestock sheet that form
side edges 298 and a bottom edge 300 of the carrier strip. In one
alternative embodiment, the side edges, the bottom edge, the
between label and end cuts, and the top label cut align and lie
atop the corresponding cut lines in the carrier sheet. The carrier
sheet shown in FIG. 23 can be used with the facestock sheet of FIG.
31, in appropriate alignment, to form a label sheet assembly of the
invention.
[0110] FIG. 32 shows another alternative embodiment 302 of
facestock sheet cut line patterns. The cut line pattern shown in
FIG. 32 differs from the pattern in FIG. 31 in that some of the
lines are cut through only the facestock sheet 304, while others
cut through both the facestock sheet and the carrier sheet 156.
Lines forming the bottom label cut 306 are formed in the facestock
sheet but not the carrier sheet. Lines forming the top label cut
320 can be cut through both the facestock sheet and the carrier
sheet, or through the facestock sheet only. Lines 308 between the
labels 310 and at the end edge 312 of the carrier strip 314 can be
cut through both the facestock sheet and the carrier sheet, or in
some alternative embodiments, through the facestock sheet but not
the carrier sheet because the carrier sheet cuts may already exist.
Lines forming the side edge 316 of the carrier strip and the bottom
edge 318 of the carrier strip can be cut through the facestock
sheet and the carrier sheet.
[0111] Yet another embodiment 320 of facestock cut line patterns is
shown in FIG. 33. As in other embodiments, the bottom edge 322 and
the side edges 324 of the carrier strip cuts in the facestock sheet
326 can be through the facestock sheet, or through both the
facestock sheet and the carrier sheet 156. In this embodiment, cut
lines in the carrier sheet will not underlie the labels 328. Thus,
in order for the label to be removed with the carrier strip 330,
ties 332 connect the label to the facestock portion 336 of the
carrier strip. Ties are small, uncut areas between the label and
the facestock sheet portion of the carrier strip. The ties are
located on end portions 334 of the labels, and in this embodiment,
two ties on each end are shown. The ties must be large enough, and
numerous enough, to facilitate pulling the label from the release
layer 168 on the carrier sheet, yet small enough to be easily
broken when the label is applied to the final substrate and the
carrier strip is pulled away. In one embodiment, ties are 0.010
inch long. In an alternative embodiment, ties are 0.008 inch
long.
[0112] The alternative embodiment 338 shown in FIG. 34 is similar
to the embodiment of FIG. 33, except for the addition of a tie 340
along the bottom edge 321 of the label 328. Ties along the bottom
edge of the label facilitate removal of long labels, in particular.
While one tie is shown along the bottom edge, additional ties along
the bottom edge can be present, as long as the ties are easily
broken when the label is applied to the final substrate and the
carrier strip is pulled away.
[0113] A number of exemplary carrier sheet cut line patterns and
facestock sheet cut line patterns have been provided. These and
other similarly-cut carrier sheets and facestock sheets can be
combined to provide label sheet assemblies of the present
invention. Several illustrative embodiments are now shown and
described.
[0114] One embodiment 342 of a label sheet assembly is shown in
FIG. 35. FIG. 35 shows a liner sheet 158 adhered to one side 164 of
a carrier sheet 156 with a dry-tack adhesive 166. The other side
160 of the carrier sheet is coated with a silicone release coating
168. A facestock sheet 154 is adhered to the release coated side of
the carrier sheet with a pressure sensitive adhesive 162. The cut
lines in the carrier sheet are the same as those shown in FIG. 25
and the cut lines in the facestock sheet are the same as those
shown in FIG. 32, except for the cuts forming the side edges of the
carrier strip in both the carrier sheet and the facestock sheet.
Thus, cut lines 344, 346 forming the labels 348, cut lines 350
between the labels, and small portions of the end edge 352 of the
carrier strip 354 are cut through the facestock but not the carrier
sheet (see FIGS. 36-38). The labels at least partially overlay
curved cut lines 356 in the carrier sheet. The label-overlaid
curved cut lines and cut lines 358 between the label-overlaid
curved lines are cut through the carrier sheet but not the
facestock sheet. The label-overlaid curved cut lines are shown with
two corners 360 of each label, and a substantial portion of the
adjacent side 362 of the label, overlying the carrier strip.
Alternatively, the label-overlaid curved cut line can be configured
such that more or less of the adjacent side of the label overlays
the carrier strip. Cut lines forming the side edges 364 of the
carrier strip and the bottom edge 366 of the carrier strip are cut
through the facestock sheet and the carrier sheet.
[0115] A carrier strip 368 being removed with attached labels 370
from the embodiment 342 of FIG. 35 is shown in FIG. 39. As can be
clearly seen in FIG. 39, the carrier strip includes a portion of
the carrier sheet 372 and a portion of the facestock sheet 374. In
this example, a user grasps the left edge of the carrier strip,
pulling it up and to the right. The carrier strip and the labels
that partially overlap the carrier strip are removed from the label
sheet assembly 342. Thus, a portion of the carrier sheet 372 is
separated from the liner sheet 158 and the remainder of the carrier
sheet 378, and forms part of the carrier strip. The labels are
adhered to the carrier strip by a small overlap portion 376, which
facilitates the labels peeling away from the portion of the carrier
sheet that remains attached 378 to the liner sheer. When the
carrier strip is in the peeled away position, the pressure
sensitive adhesive-coated back surfaces 380 of the labels are
exposed. In one embodiment, a dry-tack adhesive 166 may or may not
remain on the back surface 382 of the carrier strip after the
carrier strip is removed. Regardless of where the dry-tack adhesive
ends up, the carrier strip provides a tack-free handle for
manipulating the labels into a position for application to a
substrate. In an alternative embodiment in which a removable or
ultraremovable adhesive is used to adhere the carrier sheet to the
liner sheet, the adhesive can remain with the liner sheet or with
the carrier strip. If the removable adhesive remains with the liner
sheet, the back surface of the carrier strip is tack-free. If the
removable adhesive, or a portion of the removable adhesive, remains
with the carrier strip, the back surface of the carrier strip will
be tacky. However, the removable adhesive will facilitate removal
of the carrier strip from a substrate while the labels, which are
backed with a more aggressive pressure sensitive adhesive, will
adhere to the substrate. In another embodiment shown in FIG. 56,
when the carrier strip 546 and labels 548 are peeled away from the
label sheet assembly 540, a backing strip 542 is also removed and
covers the pressure sensitive adhesive-back surface 544 to protect
the adhesive. The backing strip is subsequently removed before the
labels are applied to a substrate.
[0116] FIG. 40 shows the sheet 384 of the embodiment 342 of FIG. 35
with all the carrier strips 354 and labels 348 removed. Surrounding
the area 386 where the carrier strip was adhered to the label
assembly 342 are areas 390 between the edge 388 of the label
assembly sheet and the carrier strip. These areas include portions
of the facestock sheet 154, the carrier sheet 156, and the liner
sheet 158. Areas 392 between the carrier strips also include
portions of the facestock sheet, the carrier sheet, and the liner
sheet. There are interconnected areas 394 underneath the labels and
carrier strip that include a portion of the carrier sheet and the
liner sheet after the carrier strip and labels are removed from the
label assembly sheet. There is also an area 396 underneath the
labels and carrier strip that includes the liner sheet. All of
these areas are also shown in a cross-sectional view in FIG.
41.
[0117] With the exception of the embodiment shown in FIG. 26, all
embodiments have shown a label sheet assembly that includes five
labels associated with each carrier strip, and ten carrier strips
per label sheet assembly. One skilled in the art would recognize
that the number of labels associated with each carrier strip is
easily changed by changing the length of the label. Label sheet
assemblies having three, five, eight, twelve, or any number of
labels can be produced. Likewise, one skilled in the art would
recognize that the number of carrier strips per sheet can be
changed as well. By altering the spacing between carrier strips, or
by altering the width of the carrier strip and labels, more than
ten or fewer than ten carrier strips per label sheet assembly are
possible. Accordingly, label sheet assemblies having various
numbers of labels and carrier strips fall within the scope of this
invention.
[0118] FIG. 35 shows an embodiment 342 with a portion of label side
362 adjacent two corners 360 overlying a carrier strip 354. An
alternative embodiment 398 in which the entire adjacent side 400 of
the label 410 between two corners 402 overlies the carrier strip
404 is shown in FIG. 42. In this embodiment, the entire top edge
406 of the carrier strip can be cut into the carrier sheet 156. In
an alternative embodiment, just the cut lines 408 that underlie the
labels can be cut into the carrier sheet. In these two embodiments,
the cut lines 412, 414, 416 that complete the carrier strip will be
cut through both the facestock sheet and the carrier sheet. In yet
another embodiment, the entire carrier strip can be cut into the
carrier sheet as shown in FIG. 23. Returning to the embodiment of
FIG. 42, labels are cut into the facestock sheet 154. The side
edges 418 of the carrier strip and the bottom edge 420 of the
carrier strip are cut through the facestock sheet and the carrier
sheet. The carrier strip formed in this embodiment is removed in a
similar manner to the carrier strip 368 shown in FIG. 39. In this
case, the label will be held onto the carrier strip during removal
and manipulation by a small overlap 421 between the bottom edge 400
and portions of two ends 403 of the label and the carrier
strip.
[0119] The embodiment 422 shown in FIG. 43 is one that can be
formed with all cuts made through the facestock sheet 154 of a
laminate. In this embodiment, a multi-step die 424 is used to make
the cut lines. A multi-step die is one that cuts to different
depths in a single cut. Thus, as can be seen in FIG. 44, the
cutting edge 426 cuts to a different depth than cutting edge 428.
The top-most portion 430 of the labels 432, the cut lines 434
between the labels, and the side edges 436, the end edges 440, and
the bottom edge 438 of the carrier strip 442 are made with the
first step 426 of the multi-step die cutting through the facestock
sheet and the carrier sheet. The second step 428 of the multi-step
die cuts the bottom-most portion 444 of the label. However, so that
the labels are removed with the carrier strip, several small ties
446 are provided in the cut forming the bottom-most portion of the
label. As the carrier strip is removed from the label sheet
assembly, the ties joining the label to the facestock sheet portion
of the carrier strip facilitate the label being peeled away from
the underlying carrier sheet portion. The ties will be weak enough,
though, to break when the labels are applied to the final
substrate.
[0120] An alternative embodiment to that of FIG. 43 would make use
of a single-step die 448 as shown in FIG. 45. All cuts in the label
sheet assembly are made through the facestock sheet 154 and the
carrier sheet 156. In this embodiment, the ties 446 that join the
labels 432 to the facestock sheet portion of the carrier strip 442
will overlie and cover ties in the carrier sheet since both sets of
ties are made by the same die cut. Proper choice of dry-tack
adhesive 166 joining the carrier sheet to the liner sheet 158 is
important. The adhesion of the carrier sheet to the liner sheet
must be strong enough to break the carrier sheet ties when the
carrier strip is removed, yet weak enough to allow removal of the
carrier strip from the label sheet assembly. Additionally, the
adhesion of the pressure sensitive adhesive 162 to the release
coating 168 on the carrier sheet must be weak enough to allow the
labels to be removed with the carrier strip without the facestock
sheet ties breaking, yet not so weak that the label sheet assembly
422 cannot pass through a printer or copier without the labels
separating from the label sheet assembly.
[0121] Another embodiment 448 is shown in FIG. 46. This embodiment
is similar to that shown in FIG. 42, except the labels 450 cut in
the facestock sheet 154 do not overlay any of the carrier strip
452. The cuts 454 in the carrier strip of the embodiment of FIG. 42
that would underlie the label are now located outside the cuts 456
that form the label in this embodiment. As in the embodiment of
FIG. 42, the top edge 458 of the carrier strip is cut in the
carrier sheet 156. The remaining cut lines that form the side edges
460, end edges 462, and the bottom edge 464 of the carrier strip
can be cut through the facestock sheet and through the carrier
sheet. The cuts in the facestock sheet that form the label include
ties 466 between the facestock sheet portion of the carrier strip
and the label. The ties hold the label in place on the carrier
strip when the carrier strip is removed from the label sheet
assembly 448 prior to applying the labels to a substrate.
[0122] Advantageously, in all the label sheet assembly embodiments
discussed in FIGS. 35, 39, 42, 43, and 46, the thickness of the
assembly is uniform, as seen in FIGS. 36-38. Any location on the
label sheet assembly, with the exception of any cut lines, includes
the facestock sheet 154, the carrier sheet 156, and the liner sheet
158, as well as the dry-tack 166 and pressure sensitive 162
adhesives. In products with uneven thickness, print quality can
suffer. Uniform thickness is particularly advantageous for labels
designed to be printed, where any variation in thickness can affect
the quality of indicia formed as a result of printing. For example,
indicia deposited by a laser printer in thicker areas of a label on
a label sheet assembly may not fuse as effectively as indicia
deposited in thinner areas, resulting in variable print quality.
Unevenness in the thickness of the label sheet assembly can also
affect the speed with which the label sheet assembly passes through
a printer or copier. Variations in speed during the formation of
indicia can affect the quality of the printed indicia as well.
[0123] The embodiment 468 shown in FIG. 47 includes a discontinuous
carrier sheet 470 that can be printed onto a liner sheet 158,
however the carrier sheet is very thin and does not appreciably
affect the thickness of the label sheet assembly 468. In this
embodiment, a non-adhesive coating 470 is applied to a liner sheet
that includes a silicone release layer 472. The non-adhesive
coating is applied in the shape any of the carrier strips as
previously described and shown. The facestock sheet 154 is
laminated to the liner sheet and the non-adhesive coating with a
pressure sensitive adhesive 162, resulting in an essentially
uniformly thick laminate. Cut lines 474 are made through the
facestock sheet to form labels 478. Cut lines 476 are made through
the facestock sheet and the non-adhesive coating to form the
carrier strip 480. Removal of the carrier strip results in a
non-tacky handle suitable for manipulating attached labels onto a
substrate. In alternative embodiments, the cut lines can be made
through only the facestock sheet. Removal of the carrier strip can
result in small areas of the carrier strip being tacky.
[0124] FIGS. 48-51 show various embodiments suitable for use as
side edges of a carrier strip. The embodiment 482 shown in FIG. 48
simply has rounded corners 484 at the side edge 486 of the carrier
strip 488. The embodiment 490 shown in FIG. 49 had the rounded
corners 492 at the side edge 494 accentuated by curving the end cut
inward. By accentuating the corners, the carrier strip 496 can be
more easily grasped for removal from the liner sheet 158. The
embodiment 498 of FIG. 50 includes a wavy cut at the side edge 500
of the carrier strip 502. The wavy cut creates a third corner 504
in the middle of the side edge to further facilitate removal of the
carrier strip. The embodiment 506 shown in FIG. 51 includes the top
edge 508 of the facestock sheet portion and the top edge 510 of the
carrier sheet portion of the carrier strip not being
coincident.
[0125] A method 512 of forming the label assembly sheets is
depicted in FIG. 52. A liner sheet material 158, a carrier sheet
material 156, and a facestock sheet material 154 are provided at
step 514, usually in roll form. The carrier sheet material and the
liner sheet material are unwound and laminated at step 516 together
with a dry-tack adhesive 166, and the adhesive is cured or dried to
make it non-tacky. Cut lines are then formed at step 518 through
the carrier sheet material but not through the liner sheet
material. The cuts may penetrate through the adhesive and into the
liner material, or may stop short of the liner material or the
adhesive. Separately, the facestock sheet material is unwound and
cut lines are formed at step 520 through the facestock sheet
material. The cut facestock sheet material is laminated at step 522
to the cut carrier material with pressure sensitive adhesive 162.
The laminate is sheeted at step 524 into sheets that include a
liner sheet, carrier sheet, and a facestock sheet.
[0126] An alternative method 526 includes providing rolls of liner
sheet material 158, carrier sheet material 156, and facestock sheet
material 154 at step 528. As shown in FIG. 53, the facestock sheet
material and carrier sheet material are unwound and laminated at
step 530 together with pressure sensitive adhesive 162. Cut lines
are formed at step 532 through the facestock sheet material but not
through the carrier sheet material. Cut lines are formed at step
534 through the carrier sheet material but not the facestock sheet
material. The cut carrier sheet material, along with the attached
cut facestock sheet material, is laminated at step 536 to the liner
sheet material with dry-tack adhesive 166. The laminate is sheeted
at step 538 into sheets that include a liner sheet, carrier sheet,
and a facestock sheet. In some methods, cut lines that form edges
of the carrier strip are aligned and coincident, e.g., see 420 in
FIG. 42. In these alternative embodiments, the coincident cut lines
can be formed by cutting through both the carrier sheet material
and the facestock sheet material. The cut lines can be formed from
whichever side is convenient.
[0127] In yet another alternative method 540, rolls of liner sheet
material 158, carrier sheet material 156, and facestock sheet
material 154 are provided at step 542 as shown in FIG. 54. The
carrier sheet material is laminated at step 544 to the liner sheet
material with dry-tack adhesive 166. Cut lines are made at step 546
through the carrier sheet material but not through the liner sheet
material. The facestock sheet material is then laminated at step
548 to the carrier sheet material with pressure sensitive adhesive
162. Cut lines are then formed at step 550 through the facestock
sheet material, but not through the carrier sheet material. In some
areas, the facestock sheet material cut lines are aligned and
coincident with the carrier sheet material cut lines, giving the
appearance of being cut through both the facestock sheet material
and the carrier sheet material. The label sheet assemblies are then
sheeted at step 552 into individual label sheet assemblies.
[0128] Another alternative method 554 is shown in FIG. 55. Liner
sheet material 158, carrier sheet material 156, and facestock sheet
material 154 is provided at step 556. The carrier sheet material is
laminated at step 558 to the liner sheet material using a dry-tack
adhesive 166 on one side, and laminated at step 560 to the
facestock sheet material using a pressure sensitive adhesive 162 on
the other side. Cut lines are formed at step 562 through the
facestock sheet material but not through the carrier sheet
material. Other cut lines are formed at step 564 through the
facestock sheet material and the carrier sheet material, but not
through the liner sheet material. In an alternative method, a
multi-level die 424, as shown in FIG. 44, is used to form the cut
lines through the facestock sheet material, and through the
facestock sheet material and the carrier sheet material at the same
time. After the facestock sheet material and carrier sheet material
cuts are made, the label sheet assembly is sheeted at step 566 into
sheets including the liner sheet, the carrier sheet, and the
facestock sheet.
[0129] Utilizing the above methods of making a label sheet
assembly, it is possible to form any number of sheet configurations
to include labels for staggered tabs on a set of index dividers,
folders, or the like. In addition, this technology is not limited
to desktop printable sheets or to sheets at all, as it could be
utilized to produce fan folded or roll products with unique
characteristics as well. Furthermore, the invention is not limited
to index tab labels, but may include amongst other things address
labels, or labels having a shape other than the illustrated
rectangular shape. In addition, it should be appreciated that
although all the cut lines in the various sheet assemblies are
shown as being formed orthogonal to the edges of the sheet
assembly, the cuts may be formed in a manner that is not orthogonal
to the edges of the sheet assembly.
[0130] While at least one exemplary embodiment has been presented
in the foregoing detailed description, it should be appreciated
that a vast number of variations exist. It should also be
appreciated that the exemplary embodiment or exemplary embodiments
are only examples, and are not intended to limit the scope,
applicability, or configuration of the invention in any way.
Rather, the foregoing detailed description will provide those
skilled in the art with a convenient road map for implementing the
exemplary embodiment or exemplary embodiments. It should be
understood that various changes can be made in the function and
arrangement of elements without departing from the scope of the
invention as set forth in the appended claims and the legal
equivalents thereof.
* * * * *